Method of constructing concrete vessels



Nov. 23, 1948. 'M. PALMIERI 2,454,403

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M. PALMIERI METHOD OF cons'rnuc'rme coucnmm VESSELS.

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Patented Nov. 23, 1948 UNITED STATE METHOD OF CONSTRUCTING CONCRETEVESSELS Mario Palmieri, Beverly Hills, Calif.

Application June 26, 1944, Serial'No. 542,060

2 Claims. 1

My invent-ion relates to a concrete ship or barge, and more particularlyto athin shell concrete ship or barge and the method of constructing thesame. It is a Well-known fact that vessels made out of concrete, eitherships or barges, have been built by pouring a mix of. cement, sand, andgravel, with enough Water added to it to bring about the requiredfluidity and consistency, within a mold made by two systems of forms, anoutside one and an inside one. In such systems, the construction of theforms requires use of large quantities of lumber. with the resultingwaste of the same, which makes the process of ship construction by thismethod a very expensive and very inefiicient one. Furthermore, concreteships constructed in such a way require such large amounts ofreinforcing steel that it is estimated to be from twothirds tothree-quarters of the total weight of steel required to build a completesteel ship of equal displacement. A ship constructed in acccrdance withmy invention uses much less reinforcing steel, and, because of itsdecreased dead weight and increased carrying capacity, has all thebenefits. heretofore argued for steel ships. The concrete shell informer concrete ships acts purely as a protective covering for thesteel, while in my invention the concrete acts as true structuralmaterial.

An object of my invention is, therefore, to reduce the thickness of theshell so as to bring about an increase in carrying capacity.

Another object of my invention is to construct a concrete vessel wherebythe outer shell is relieved of the task of taking care of stressoriginated from bending in a longitudinal direction, and these stressesare taken care of by continuous longitudinal bulkheads integral with thekeel and main strength deck. 4

Another object of my invention is to eliminate many of the transverseribs by spacing them further apart, relying on the shell, transversebulkheads and stringers to redistribute the stresses.

Another object is to eliminate the need of double forms and use eitherone of the following types of forms, that is, an inside, a central, oran outside form, whichever the design of the vessel dictates, thuspermitting the application of pneumatically applied concrete in allplaces.

Another object is to eliminate the need of wood forms, and to useclosely woven steel mesh both as a form and as a reinforcing member.

Another object is to reduce the amount of reinforcing steel needed tomake the vessel resistant to the nature and magnitude of the stresses towhich it is subject.

Another object is to construct a vessel so that pre-fabri-cated sectionsof reinforcing steel can be installed either complete, or in layers,thus eliminating the need tor shooting the pneumatically appliedconcrete through thick sections of reinforcing steel, and consequentlyassuring" a perfect bedding for each layer as it is applied, andeliminating sand pockets behind'the reinforcing steel. 1 i

Another object is to utilizehigher values of ulti mate stresses ofconcrete which are pneumatically applied rather than placed by puddling.

A further object is to apply the principle of the arch to shipconstruction, thereby utilizing the higher compressive strength ofconcrete. By pneumatically applying the concrete in thin layers, Lamable to construct a ship which consists of a series of layers ratherthan a single layer of concrete. An advantage achieved by this method ofconstruction, is that any cracks developing in the concrete arecoveredand welded closed by the successive layers of concrete which arepneumatically sprayed over the first layers,thus assuring asubstantially water-tight construction not possible in a onelayerconstruction.

Other objects and advantages of my invention will be apparent from thefollowing description of the preferred embodiments thereof.

In the drawings:

Fig; 1 is a cross-section taken on midship.

Fig. 2 is a cross-section taken in perspective.

Fig. 3 is a perspective of a cross-section.

Fig. 4 is a cross-section of a modification.

Fig. 5 is a cross-section of the reinforcing steel.

Fig. 6 is a cross-section.

Fig. 7 is a cross-section of the keel construction.

Fig. 8 is a cross-section.

Fig. 9 is a perspective cross-section.

Fig. 10 is a cross-section.

Fig. 11 is a cross-section.

In constructing a ship or barge in accordance with my invention, I firstconstruct a light wood form I shaped to follow the contour of each rib,which comprises one edge or face 2 and one side only 3. Openings 4 areprovided intermittently to allow for the continuity of the longitudinalstringers 5. Holes 8 are drilled intermittently along the face 2 for thefull length, through which small rods 9- are inserted and extend '2"beyond the inside and outside faces of the concrete ribs l0. Woodenstringer forms ll composedof one face and one side are installed betweenthe rib forms I up the sidesof the ship, and girder forms l-Z betweenthe ribs- I along, the bottom. Light weight welded steel trusses [3 arethen installed 3. in each rib form, and longitudinally reinforcing steelI4 is placed in each stringer form H and girder form l2 and securelyanchored to the rib steel trusses l3. Pre-assembled sections of thelongitudinal bulkhead l5 and pre-assembled sections of the transversebulkhead steel l6 are then installed and welded in place. A layer ofonequarter of an inch wire cloth I1 is inserted at the center line. Ithen pneumatically apply concrete in thin layers on all sides of theforms 2 and 3 of the required thickness, thereby eliminating the use ofcomplete wooden forms and by the use of the wire cloth I! the entirecenter longitudinal bulkhead can be constructed without the use ofwooden forms. After the pneumaticall; placed concrete has been appliedto form the center longitudinal and transverse bulkheads as well as theframework of the ribs, stringers and girders, and has reached the stateof hardness such as to guarantee a substantial value of ultimatecompressive strength, the wood forms I, I I and 12 are removed andlayers of wire mesh l3 (see Fig. 3) are attached to the inside andoutside faces of the ribs [0 by inserting over the projecting ends I9 ofthe bars 9, and bending the ends of the bars as at so as to securelyanchor and hold the mesh It to the fact of the ribs Ill. The mesh l8spans the space between the ribs 2| and the girders, and acts as a formupon: which a layer of pneumatically applied concrete can be placed. Asecond layer of mesh is then applied to the inside and outside faceunder the same process of anchoring to the bars 9, and pneumaticallyapplied concrete is built up to the final thickness required so as tocompletely bury all the steel, mesh and fastenings, well below theexterior surface of the concrete.

A modification of my invention by which a ship or barge can beconstructed, is shown in Fig. 6. I first pre-assemble sections of thehull steel 24, which has a layer of fine mesh inserted between thelongitudinally extending steel 25a which acts as a form upon whichconcrete of any thickness can be applied by pneumatically spraying thesame thereon in layers. After the sections of the hull steel have beencompletely assembled and welded together, pneumatically placedponcreteis applied to the lower half of the hull and allowed to cure until ithas reached sufficient compressive strength to insure the safecompletion of the installation of the remaining pre-assembled steelsections 21, after which the remaining pressurised concrete is appliedunder the same process to build up the stringers, girders, and keels.

In applying theconcrete, a base coat is shot on both sides of the mesh25 to a thickness of approximately one inch. The initial shrinkage ispermitted to take place and the curing of the material is started beforea second coat is applied, so that any shrinkage of temperature cracksare completely sealed with the application of successive coats, thusassuring a positive dense packing of the material. By building up thesedense areas in successive layers or laminations, the heat generatedthrough the hydration of the cement, so detrimental to the quality ofthe finished product, is eliminated, thus assuring the lack of greatchangesin temperatures and stresses. Other layers can be applied tobuild a section up to the line of final or complete coat which isapplied in one continuous coat over the entire compartment area. Inconstructing a ship or barge with this method, no wood forms of any typeare required. I

A modification of my invention comprises constructing a ship ofpro-formed ribs. These are constructed as shown in Fig. 9. I use a woodform 32 to the shape and thickness of the hull and ribs. Sections ofpipe 33 are placed intermittently in the forms 32, and lengths of steelbars 34 are inserted to which stringer bars 35 are welded. Light weightsteel trusses 36 are then welded to the stringer bars34. Dowels 3'! arewelded intermittently to the trusses 36 which are folded over the hullsteel 38 to anchor it securely to the ribs 39. After all steel is placedin the rib forms 32, I pneumatically apply concrete to build up to therequired shape, leaving the ends tapered at approximately a angle toform a bonding surface ll). These pro-formed ribs are then assembled andheld in place by the transverse steel of the deck girders 4! which arealso attached to a center longitudinal bulkhead 42 which is constructedby forming a grid of steel members over which is placed a wire meshscreen against which pneumatically shot concrete can be placed to buildup the center longitudinal bulkhead 43. The reinforcing steel 38 is thenapplied to the exterior face and contours of the ribs 39 after thewooden forms 32 have been removed, and a layer of wire mesh 44 insertedbetween the reinforcing steel 38 upon which the exterior face of theship can be pneumatically applied to the desired thickness.

In accordance with my method of construction,

all structural members of the ship or barge, and the exterior surfaceribs and central longitudinal bulkhead and all other bulkheads, can beconstructed by forming a grid of reinforcing steel through the center ofwhich isplaced a wire mesh screen upon which layers of concrete can bepneumatically shot. By this construction the concrete is completelyexposed to the person applying the same, thus preventing any defectiveworkmanship. By applying concrete in layers rather than in one solidmass, a safer curing of the concrete is achieved, which results in theminimum of cracks, and one layer completely seals the cracks in thelayer below. These layers of concrete bond thoroughly together and forman integrally monolithic structure, thus forming a ship or barge whichhas a monolithic construction.

' In Fig. 1 is shown a cross-section of a preferred form of a ship builtin accordance with my invention. However, in this figure the reinforcingsteel has been left out for purposes of clarity, but it is to beunderstood that the same should be applied in all forms as shown inFigs. 2 and 3.

A'ship constructed in accordance with my invention, comprises an outershell 54 which runs continuously around the exterior of the ship.Longitudinal reinforcing ribs 55 strengthen the outer shell 54. I preferto use a double bottom 56 which rests on the longitudinal ribs 55. Itshould be remembered that all of the ribs and shell are built up and theinner bottom 56 is built up by applying the concrete pneumatically, thusbonding all of the structure together into a monolithic construction. Onthe center line of the ship is placed a central longitudinally extendingbulkhead 51. This'bulkhead eliminates many of the cross-sectional ribsand takes much of the strains and stresses placed on the hull, thuspermitting the entire hull to be made thinner and of lighter weight. Thedeck 58and intermediate decks 59 are similarly constructed of concreteand bonded to the shell 54 and center bulkhead 51.

5 I claim: 1. A process of constructing concrete ships, comprising theerection of twosided forms for the ribs, placing reinforcing steel insaid forms,

Welding transverse and longitudinal bulkhead 5 reinforcing steel to saidrib steel, attaching a wire cloth to said bulkhead steel pneumaticallyshooting concrete under pressure into said forms to build up said ribsand pneumatically applying concrete in successive layers to build upsaid bulkheads, connecting said ribs and bulkheads to each other with awire mesh screen to form the exterior shell and decks of said ship,pneumatically shooting concrete in layers on both sides of said mesh toform the exterior shell and decks of said ship and. to bond saidexterior shell, decks, ribs and bulkheads together.

2. A process of constructing concrete ships, comprising the erection oftwo-sided forms for the ribs, placing reinforcing steel in said forms,welding transverse and longitudinal bulkhead reinforcing steel to saidrib steel, attaching a wire cloth to said bulkhead steel welding steelrods which extend beyond the finished bulkheads and ribs to saidreinforcing steel, shooting concrete under pressure into said forms andonto said wire cloth to build up said ribs and bulkheads, connectingsaid ribs and bulkheads to each other with a wire mesh screen to formthe exterior shell and decks of said ship and holding said wire meshscreen in place by said projecting steel rods, and pneumaticallyshooting concrete in layers on both sides of said mesh to form theexterior shell and decks of said ship and to bond said exterior shell,decks, ribs and bulkheads together.

MARIO PALMIERI.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 984,285 McNeillie Feb. 14, 1911991,780 Holm May 9, 1911 1,258,726 White Mar. 12, 1918 1,267,668Kennelly May 28, 1918 1,307,224 Weber June 17. 1910

